Performance Influencing Factors and Research Progress of Packer Rubber under HPHT and Corrosive Downhole Conditions

Chen-Kai Zhang

doi:10.18535/ijsrm/v13i05.ms01

Abstract

Abstract

The packer is an indispensable sealing tool in oil and gas well completion and intervention operations; its sealing performance directly affects downhole safety and efficient hydrocarbon production. As the core sealing component of the packer, the packer rubber must maintain stable performance in extreme downhole environments characterized by high temperature, high pressure, strong corrosion, and long service life. This paper systematically reviews, from the perspectives of material properties, aging behavior, stress relaxation, corrosion effects, and structural design, the key factors affecting packer rubber sealing performance. It also analyzes recent domestic and international advances in the design and development of high-performance packer rubbers. Studies show that high-performance elastomers such as AFLAS and FKM exhibit superior mechanical strength and chemical stability in high-temperature, high-corrosion environments compared to conventional HNBR. During service, however, rubber materials tend to undergo stress relaxation, causing a significant drop in contact stress and a concomitant decline in sealing performance. Furthermore, downhole fluid corrosion leads to rubber embrittlement and strength degradation, which in turn can trigger seal failure. On the structural side, optimizing compression ratios, controlling interface friction, and introducing anti-“shoulder extrusion” features all effectively enhance sealing reliability. Under multiphysics coupling, numerical simulations combined with experimental validation are currently the prime means of improving service-life prediction accuracy and design optimization efficiency. In summary, improving packer rubber performance requires coordinated optimization of material selection, structural compatibility, and mechanical behavior control. The findings in this review provide important guidance for designing packer sealing elements under complex well conditions and offer key technical support for intelligent completions and green, efficient oilfield development.

Keywords: packer rubber; high temperature and high pressure; sealing performance; stress relaxation; corrosive environment; elastomer materials; structural optimization; multiphysics coupling

References

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[refR-2] J. Liu, L. Dang, M. Fu et al., Mechanical Analysis of Large Axial Compression Deformation and Double Contact of Packer Rubber Cylinder, Pet. Mach., 2014, 42(7), p 49-55.Google Scholar ↗

[refR-3] Y. Dou, S. Xue, and Y. Cao, “Coupled analysis of pressure and volume in multiple annuli of high-temperature high-pressure well casings,” Petrol. Mach., vol. 44, no. 1, p. 4, 2016,Google Scholar ↗

[refR-4] Baojun D ,Wei L ,Lin C , et al.Investigation on mechanical properties and corrosion behavior of rubber for packer in CO2-H2S gas well[J].Engineering Failure Analysis,2021,124Google Scholar ↗

[refR-5] X. Yan, L. Jun, L. Gonghui et al., A new numerical investigation of cement sheath integrity during multistage hydraulic fracturing shale gas wells, J. Nat. Gas Sci. Eng., 2018, 49, p 331-341.Google Scholar ↗

[refR-6] Yu. Yuan Jinping, L.S. Yongjin et al., Technical difficulties and countermeasures for shale gas horizontal well cementing in Weiyuan block, Nat. Gas Ind., 2016, 36(3), p 55-62.Google Scholar ↗

[refR-7] H. Alan, F. Total, R. Robert et al., Delivering a Fully Qualified HP/HT Production Packer Following Field Failure, SPE, 2009, 105736, p 191–199.Google Scholar ↗

[refR-8] B. Dong, D. Zeng, Z. Yu, L. Cai, S. Shi, H. Yu, H. Zhao, G. Tian, Corrosion Mechanism and applicability assessment of N80 and 9Cr Steels in CO 2 drive, J. Mater. Eng. Perform. 28 (2) (2019) 1030–1039.Google Scholar ↗

[refR-9] Y.S. Choi, S. Hassani, T.N. Vu, S. Nesic, A.Z.B. Abas, Effect of H Corrosion 72 (8) (2016) 999–1009. 2 S on the corrosion behavior of pipeline steels in supercritical and liquid CO auxiliary steam 2 environments,Google Scholar ↗

[refR-10] Y. Yao and X. Wang, "Exploration and practice of 7-5/8″ packer retrieval technology in Bohai Sea," Petrochemical Technol., vol. 32, no. 3, pp. 39-40+35, 2025.Google Scholar ↗

[refR-11] B. Wang, H. Guo, J. Sun et al., "Simulation of microchannel leakage and sealing mechanism study for high-temperature high-pressure packers," in Proc. 2024 Int. Conf. Oil Gas Field Explor. Dev., vol. I, Xi'an Shiyou University and Shaanxi Petroleum Society, 2024, pp. 1686-1697.Google Scholar ↗

[refR-12] Q. Yue, G. Wang, J. Liu et al., "Nonlinear flow simulation calculation of expandable packer rubber under high temperature and high pressure," Chinese J. Comput. Mech., vol. 40, no. 3, pp. 411-423, 2023.Google Scholar ↗

[refR-13] Kai C ,Leiwang S ,Hui L , et al.A novel degradable sealing material for the preparation of dissolvable packer rubber barrel[J].Journal of Macromolecular Science, Part A,2023,60(3):207-216.Google Scholar ↗

[refR-14] Lan W ,Wang H ,Zhang X , et al.Sealing properties and structure optimization of packer rubber under high pressure and high temperature[J].Petroleum Science,2019,16(3):632-644.Google Scholar ↗

[refR-15] W. Cheng, Z. Guo, Q. Zhang, et al., “Development and application of packers for ultra-high temperature and high pressure oil and gas wells,” Petroleum Drilling & Production Machinery, vol. 54, no. 1, pp. 53–61, 2025. 1Google Scholar ↗

[refR-16] Bo L ,Sheng-xin L ,Ming-xue S , et al.Tribological behaviour of acrylonitrile-butadiene rubber under thermal oxidation ageing[J].Polymer Testing,2021,93Google Scholar ↗

[refR-17] Farzaneh H ,H. N F ,Ryan N , et al.The impact of thermal ageing on sealing performance of HNBR packing elements in downhole installations in oilfield wellhead applications[J].Journal of Petroleum Science and Engineering,2022,208(PB):Google Scholar ↗

[refR-18] Xu Z ,Bin L ,Gensheng F .Evaluation of sealing performance of a compression packer at high temperature.[J].Science progress,2022,105(1):368504221079180-368504221079180.Google Scholar ↗

[refR-19] B. Li, F. Yu, X. Zheng, et al., “Effect of rubber stress relaxation behavior at high temperature on sealing performance of packers,” Chinese Journal of Applied Mechanics, vol. 37, no. 5, pp. 2153–2159, 2330–2331, 2020.Google Scholar ↗

[refR-20] Yue Q ,Wang X ,Liu Y , et al.Failure evaluations for packers in multistage fracturing technology with immobile strings[J].Journal of Petroleum Science and Engineering,2021,206Google Scholar ↗

[refR-21] Baojun D ,Wei L ,Lin C , et al.Investigation on mechanical properties and corrosion behavior of rubber for packer in CO2-H2S gas well[J].Engineering Failure Analysis,2021,124Google Scholar ↗

[refR-22] Wang C P ,Chen H M ,Jenkinson J , et al.Interfacial friction effects on sealing performances of elastomer packer[J].Petroleum Science,2024,21(3):2037-2047.Google Scholar ↗

[refR-23] S. Chen, Y. Luo, F. Qiu, et al., “Contact mechanical behavior and setting performance evaluation of compression packers,” Journal of Xi’an Shiyou University (Natural Science Edition), vol. 34, no. 4, pp. 82–88, 2019.Google Scholar ↗